1989 Chevy 2500 Lift Kit Install and More - Sign of the Times

Before: Complete with stainless... 

   

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Before: Complete with stainless steel side steps and hideously large side mirrors. We couldn't wait to work our magic.

Today the inevitable has come to pass. Less and less people are interested in dumping gobs of cash into off-road toys. We've had to embrace the reality of what people are actually willing to spend their hard-earned cash on. In doing so we've come to realize that older, less expensive pickups make a whole lot more sense to build. So, we decided to showcase a build that adheres to a strict policy of economic reform, cost cutting and unbeatable value. Our mission was to transform a $500 beater pickup into a Baja-worthy prerunner and support rig. We took our time searching for the perfect balance of dependably and form. The truck we found was offered online for a great deal. The ad read: $500, 1989 Chevy 2500, 2WD, all original, one owner. We contacted a friend who lived in the same region of our perspective purchase, to see if he would look it over for us. Our buddy got back to us with good news. "Aside from a little dent in the left rear fender it's a clean truck". Happy with the report of an amazingly clean $500 truck, we wired the money and arranged a time to pick up our new (used) prize. A few weeks later we tested the rig the way we got it. We hitched it to a flatbed trailer and hauled a side-by-side to Pismo State Beach for a photo shoot. The truck ran fine, despite having more than140,000 miles on the odometer. Apparently the previous owner used the rig solely as a tow truck for a small travel trailer. Large aftermarket towing mirrors, an old school fiberglass Donco utility cover and fifth-wheel hitch were pretty good indicators of its past life. Now, we had a whole different intention for "Grandpa's tug boat," as a group of friends in Pismo dubbed it. Our mission was clear: Strip everything originally installed by the previous owner and modify the rest so that the rig could hold it's own on in Baja California during the upcoming Baja 1000 race. Good looks didn't hold nearly as much weight as function, yet we knew with a few weekend makeover sessions this tug boat could go from zero to hero for less than $8,000. Follow along now as we stimulate our beater with affordable products that make all the difference.

After: What a difference $7,200...        read full caption After: What a difference $7,200 in aftermarket attention makes.	Our first call to action was...        read full caption Our first call to action was gaining the appropriate lift required to squeeze in 33-inch tall tires. We took the rig down to RCD Suspension in El Cajon, California, to have their 6-inch drop bracket suspension system installed. Here you can see the difference between the RCD knuckles and the factory units. We like that these knuckles are cast from iron and then CNC machined to ensure perfect steering geometry. These knuckles make up the heart of the RCD system.	This shot shows the new front...        read full caption This shot shows the new front RCD coil spring next to the old factory spring. The progressive rate coil springs RCD provides with the system are well-though out and perfectly engineered for our application. These springs are hot wound, shot peened and pre-set (Each coil spring is fully tested and inspected prior to shipment). They are set up to maintain a smooth and comfortable ride while increasing front wheel travel by 20 percent.
Up front the RCD kit utilizes...        read full caption Up front the RCD kit utilizes a pair of longer Bilstein monotube shocks to improve ride characteristics.	Again, the rear portion of...        read full caption Again, the rear portion of the kit includes a pair of Bilstein monotube shocks-a distinct improvement over the worn out factory dampers.	Check out the CNC machined,...        read full caption Check out the CNC machined, zinc plated billet steel sway bar links with over-size urethane bushings to optimize sway bar geometry and function
We were surprised to see both...        read full caption We were surprised to see both of the included stainless steel "Twin-Link" anti-compression strut bars were beautifully TIG welded to the bushing housings to insure structural rigidity to the front drop down assembly. RCD is the only suspension manufacturer that we know of that goes to that much trouble to make a simple brace look good under the truck.	Here you can see the two heavy-duty...        read full caption Here you can see the two heavy-duty steel lower sub-frame assemblies as they were installed under the front of the truck. These assemblies have a durable Polyurethane powder coat finish for long lasting good looks.	The last item RCD installed...        read full caption The last item RCD installed during the process was the stainless steel "Twin -Link" anti-compression strut bars. These braces triangulate the lower drop down assemble giving it plenty of strength for years of hard bashing.
The most difficult part of...        read full caption The most difficult part of the suspension installation was installing the front coil springs. The easiest technique to accomplish this in a shop is by combining the compression force of a tranny jack with a few solid blows from a small sledge hammer as shown here. Notice how the RCD technician used a wooden block to protect the coil's finish.	After driving the truck, lifted...        read full caption After driving the truck, lifted on 33-inch tires, for a few weeks we decided a re-gear was in order. The factory 3.73:1 gearing left the truck feeling a bit sluggish off the line. So we scored a set of 4.56:1 gears for the rear semi-float 14-bolt axle. Randy's Ring and Pinion supplied us everything we needed for the re-gear process, including a master installation kit and the superb Eaton E-Locker differential. We like the E-Locker because it allows the end user the choice of a fully locked or open differential at the touch of a button. The good folks at Right Gear and Axle in Salinas, California, performed the installation in during a brief afternoon visit.	To attain a more supple rear...        read full caption To attain a more supple rear ride quality we contacted the leaf spring experts at Deaver Spring in Santa Ana, California. After a brief phone conversation about the truck, the Deaver technician recommended that a pair of mini leaf packs be installed in place of the factory overload leafs. A few days later we took a drive to Deaver to have the upgrade performed. This new arrangement allows the spring to flex well while providing a much smoother ride quality. The load carrying capacity was reduced significantly, but that's a trade off we could live with.
A full month of driving the...        read full caption A full month of driving the truck all over California gave us a pretty good idea of what was needed next. Despite the simplicity of the RCD rear leaf spring blocks, we knew our $500 beater needed a softer rear spring arrangement. The factory overload leaf left the rear suspension firm and even harsh at times.	Tires and Wheels Our friends...        read full caption Tires and Wheels Our friends at Off Road Warehouse in El Cajon, California, mounted up a set of 33-inch Nitto Terra Grappler A/Ts on Centerline's polished Wolverine wheels. We liked these particular wheels because they are super strong, thanks to their one-piece, rotary forged design. Manufactured to precise tolerances using T-6061 billet aluminum, these wheels feature a 3,200-pound load rating per wheel and come with a 3-year luster warranty. We were impressed that the worst of these tires and wheels only needed 2 ounces of lead to balance out perfectly. That said a lot about how true both the tire and wheels were.	Once fitted to the truck we...        read full caption Once fitted to the truck we had RCD do a temporary trim job on the rear corners of the front bumper to prevent rubbing. Soon after we had GM Truck Center in Burbank, California, build us a custom prerunner front bumper complete with winch mount and tabs for auxiliary LED lights.